CN110404985A - A kind of cold bed intelligence control system and its application method based on machine vision - Google Patents
A kind of cold bed intelligence control system and its application method based on machine vision Download PDFInfo
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- CN110404985A CN110404985A CN201910809024.4A CN201910809024A CN110404985A CN 110404985 A CN110404985 A CN 110404985A CN 201910809024 A CN201910809024 A CN 201910809024A CN 110404985 A CN110404985 A CN 110404985A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
- B21B1/22—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling plates, strips, bands or sheets of indefinite length
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B37/00—Control devices or methods specially adapted for metal-rolling mills or the work produced thereby
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B43/00—Cooling beds, whether stationary or moving; Means specially associated with cooling beds, e.g. for braking work or for transferring it to or from the bed
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
- B21B1/22—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling plates, strips, bands or sheets of indefinite length
- B21B2001/225—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling plates, strips, bands or sheets of indefinite length by hot-rolling
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Abstract
Disclosed by the invention is a kind of cold bed intelligence control system based on machine vision, cold bed, image collecting device, control host, communication server and the monitoring display equipment executed including PLC control, image collecting device adapting device is in the top of cold bed, for obtaining the image information in cold bed region；Control host connect setting with image collecting device and monitoring display equipment phase control respectively, and controls host and connect setting with cold bed phase control by communication server；Communication server is also connected setting with monitoring display equipment.The application method for the cold bed intelligence control system based on machine vision that invention further discloses a kind of.The present invention realizes that cold bed control is changed from traditional manual to automation and intelligentification, realize the high-precision control and Fast Logical processing of cold bed control technology, to promoting steel and iron industry process intelligent development to be of great significance, there is obvious action to steel and iron industry whole process production efficiency is improved.
Description
Technical Field
The invention relates to the field of hot rolled steel plate production, in particular to a machine vision-based cooling bed intelligent control system and a using method thereof.
Background
The cooling bed is an important part of the production process of the medium plate, on one hand, the cooling bed provides enough air cooling time for the steel plate, releases stress, ensures the performance and the plate shape, and on the other hand, the cooling bed plays a role in caching the production process and controls the whole production rhythm. At present, almost all the cooling beds of the hot rolling medium plate production line in China are manually controlled and mechanically automated methods, and the operation has obvious defects:
firstly, empirical operation, namely the current cooling bed operation, is mainly characterized in that specific operators judge whether a steel plate is put into a cooling bed or not, whether the steel plate moves or not and the like according to own experience, and the requirements of standardized production cannot be met.
Secondly, the efficiency is low, and because the production line is in a real-time running state, individuals cannot realize the real-time control of the whole cooling bed area, the efficiency is low, and the efficiency even becomes a factor restricting the production and cannot meet the requirement of the matching of the rolling process.
The control precision is poor, different teams and groups have different operation details, and different people have different operations, so that the subjective influence on the control of the cooling bed and the control of the steel plate is large, and the requirement of high-precision error-free production cannot be met.
Therefore, the conversion of the traditional manual control to the automatic intelligent control of the cooling bed is realized, the method has important significance for improving the cost advantage and the technical advantage of the steel enterprise, and in the industrial 4.0 era, the cooling bed control technology with high-precision control and rapid logic processing is developed, cooling bed control equipment matched with the cooling bed control technology is developed, the method has important significance for promoting the intelligent development of the steel industrial process, and the method has obvious effect for improving the whole process production efficiency of the steel industry.
Disclosure of Invention
The invention discloses a machine vision-based cooling bed intelligent control system and a use method thereof, and mainly aims to overcome the defects and shortcomings in the prior art.
The system comprises the steps of obtaining an image of a target area of a cooling bed, segmenting and processing the obtained image, and processing the image by a GPU (graphics processing unit) acceleration technology in a construction process, namely, data collected from an industrial camera is transmitted to a host through a data collection software and hardware system, an image processing module and a logic processing module at the host are triggered, original image data are converted into actually available data through a series of image processing programs and transmitted to a logic end, the logic end performs logic control on the whole cooling bed through the image processing data, a control instruction is sent to a PLC (programmable logic controller) for cooling bed behavior control, and a command is sent to a server for information updating control.
On the other hand, the system controls the cooling bed by means of machine vision, and mainly realizes information perception and dynamic perception of equipment to a cooling bed area, feeds back a perception result to a logic part to give a command and correction, and finally realizes deep learning of various control data generated by the cooling bed by constructing a deep learning machine neural network and an intelligent algorithm so as to realize self-state judgment and control of the cooling bed.
The technical scheme adopted by the scheme is as follows:
a machine vision-based intelligent cooling bed control system comprises a cooling bed, an image acquisition device, a control host, a communication server and a monitoring display device, wherein the cooling bed is controlled and executed by a PLC (programmable logic controller), and the image acquisition device is matched with the device and arranged above the cooling bed and used for acquiring image information of a cooling bed area; the control host is respectively connected with the image acquisition device and the monitoring display equipment phase control, and is connected with the cooling bed phase control through the communication server; the communication server is also connected with the monitoring display equipment.
Furthermore, the image acquisition device comprises six industrial cameras with high resolution, laser transmitters and trigger signal controllers, the six industrial cameras are respectively and symmetrically arranged above two sides of the cooling bed, the laser transmitters are used for assisting in positioning the position of the steel plate, the trigger signal controllers are respectively connected with the industrial cameras and the control host, and the trigger signal controllers are activated by image signals of the industrial cameras and then are connected with the control host.
Furthermore, the control host comprises an image processing module and a logic processing module, the image processing module is respectively connected with the image acquisition device and the logic processing module, and the logic processing module is connected with the cooling bed phase through the communication server in a control mode.
Furthermore, the logic processing module is also constructed with a deep learning convolution neural training network and an intelligent algorithm, and is used for deep learning and training various control logic instructions generated by the cooling bed, and intelligently identifying and judging the control state of the cooling bed.
A use method of a machine vision-based cooling bed intelligent control system comprises the following specific steps:
the method comprises the following steps: acquiring a cold bed image, namely acquiring an image of a cold bed area by an image acquisition device arranged above a cold bed, and transmitting collected image data information to a control host to finish data acquisition and transmission;
step two: image processing, namely, the control host performs target selection and perspective transformation processing on the image data information uploaded in the step one;
step three: filtering the image, namely filtering the image subjected to perspective transformation in the step two by adopting a median filtering denoising algorithm to remove noise points of the image;
step four: performing steel plate image segmentation, namely performing threshold segmentation on the target image obtained in the step three by adopting an OTSU threshold processing algorithm to completely extract the steel plate target image from the image, forming a whole or partial pixel set of the steel plate target image, and finally finding out a partial or whole outline of the steel plate target image;
step five: and image data is accelerated, a GPU image acceleration processor is adopted to convert and transmit original image data to a logic end of a control host, the logic end carries out logic control on the whole cooling bed through the obtained image processing data, sends a control instruction to a PLC for controlling the cooling bed behavior, and sends a command to a communication server for information updating control.
Further, the image processing in the second step includes the following specific steps:
(1) selecting a target area, namely adaptively selecting four coordinate points in an image, wherein a quadrangle formed by enclosing the four coordinate points comprises the target area to be processed;
(2) perspective transforming the image, mapping the image of the selected target area from a two-dimensional view plane to a three-dimensional view plane by using the following mapping formula,whereinrepresenting points before transformation, before transformation𝑤A value of 1, (U, V, 1) in three-dimensional representation, mapped to three-dimensional by matrix transformation；
Then the image is mapped again from the three-dimensional view plane to the two-dimensional view plane by using the following mapping formula,and completing perspective transformation processing of the image.
Further, the specific steps of adaptively selecting four coordinate points in the step (1) are as follows:
A. acquiring relevant parameters of a camera, wherein the relevant parameters of the camera comprise a field range and an angle alpha of camera shooting, and the arrangement height h of the camera0Distance l from camera to laser line0Distance l from camera to the nearest side of cooling bed1And the width l of the laser line obtained by cutting2；
B. Calculating by using the obtained camera parameters and the calculation formula of the side length of the right triangleObtaining the horizontal linear distance l from the camera to the nearest side of the cooling bed3And the horizontal linear distance l from the camera to the laser line4；
C. Width l of laser line obtained by cutting2Obtain the coordinates w of two end points1And w2；
D. By calculating l4And l3And the coordinate point w1And w2Four coordinate points p of the target area can be obtained1，p2，p3，p4。
Furthermore, the logic control in the fifth step further comprises the step of using a convolutional neural training network and an intelligent algorithm for constructing deep learning, and performing deep learning and training on various control logic instructions generated by the cooling bed, and intelligently identifying and judging the control state of the cooling bed.
As can be seen from the above description and illustration of the present invention, the advantages of the present invention compared to the prior art are:
according to the scheme, the control of the cooling bed is realized by means of machine vision, the equipment can sense and dynamically sense the information of the cooling bed area, can feed back to a logic part according to a sensing result to give a command and correct, and finally, by constructing the learning of a deep learning machine neural network and an intelligent algorithm, the learning of various control data generated by the cooling bed is realized, and the self-state judgment and control of the cooling bed are realized. The scheme realizes high-precision control and rapid logic processing control of equipment, realizes intelligent operation of a cooling bed control technology, promotes intelligent development of the steel industry process, and has a remarkable effect of improving the whole process production efficiency of the steel industry.
Drawings
FIG. 1 is a system block diagram of the present invention.
Fig. 2 is a schematic diagram of the distribution structure of the image acquisition device of the present invention.
Fig. 3 is a schematic view of the shooting of the industrial camera of the present invention.
Detailed Description
Embodiments of the present invention will be further described with reference to the accompanying drawings.
As shown in fig. 1 to 3, an intelligent cooling bed control system based on machine vision includes a cooling bed 1 controlled and executed by a PLC, an image acquisition device 2, a control host 3, a communication server 4, and a monitoring display device 5, where the image acquisition device 2 is installed above the cooling bed 1 in a matching manner, and is used to acquire image information of a cooling bed area; the control host 3 is respectively connected with the image acquisition device 2 and the monitoring display device 5 in a control mode, and the control host 3 is connected with the cooling bed 1 in a control mode through the communication server 4; the communication server 4 is also connected with the monitoring display device 5.
Further, as shown in fig. 1 and 2, the image capturing device 2 includes six industrial cameras 21 with high resolution, six laser transmitters 22 symmetrically disposed above two sides of the cooling bed 1, and a trigger signal controller (not shown in the figures), wherein the laser transmitters 22 are used for assisting in positioning the position of the steel plate, the trigger signal controller is respectively connected to the industrial cameras 21 and the control host 3, and the trigger signal controller is activated by the image signal of the industrial cameras 21 and then connects the industrial cameras 21 to the control host 3.
Furthermore, the control host comprises an image processing module and a logic processing module, the image processing module is respectively connected with the image acquisition device and the logic processing module, and the logic processing module is connected with the cooling bed phase through the communication server in a control mode.
Furthermore, the logic processing module is also constructed with a deep learning convolution neural training network and an intelligent algorithm, and is used for deep learning and training various control logic instructions generated by the cooling bed, and intelligently identifying and judging the control state of the cooling bed.
A use method of a machine vision-based cooling bed intelligent control system comprises the following specific steps:
the method comprises the following steps: acquiring a cold bed image, namely acquiring an image of a cold bed area by an image acquisition device arranged above a cold bed, and transmitting collected image data information to a control host to finish data acquisition and transmission;
step two: image processing, namely, the control host performs target selection and perspective transformation processing on the image data information uploaded in the step one;
step three: filtering the image, namely filtering the image subjected to perspective transformation in the step two by adopting a median filtering denoising algorithm to remove noise points of the image;
step four: performing steel plate image segmentation, namely performing threshold segmentation on the target image obtained in the step three by adopting an OTSU threshold processing algorithm to completely extract the steel plate target image from the image, forming a whole or partial pixel set of the steel plate target image, and finally finding out a partial or whole outline of the steel plate target image;
the purpose of image segmentation is to segment a target or an interested part in an obtained image, and parts needing processing in a steel plate image have two aspects, namely laser line segmentation and laser line data extraction. The laser line segmentation aims at realizing the positioning of the steel plate at the position of the cooling bed, so as to depict the distribution condition of the steel plate on the cooling bed; the positioning of the steel plate on the cooling bed is related to whether a new steel plate can be put on the cooling bed or not, and the distribution of the steel plate on the cooling bed is related to the operation strategy of the cooling bed. The accurate position depiction is the first step of realizing intelligent control of the cooling bed, and the processing capacity directly reflects the intelligent processing capacity of the cooling bed.
The OTSU is a method for determining a threshold value by calculating the maximum variance of the gray distribution of an image based on a gray histogram of the image, and binarizes the image through the threshold value. The algorithm first assumes that there are two classes of pixels in the image, namely the target pixel and the background pixel, and in general, to classify the data, it can be calculated that its intra-class variance is minimized or its inter-class variance is maximized. The OTSU method is to find the threshold value when the inter-class variance is maximized, because larger inter-class variance means smaller probability of false score.
The mathematical expression process of the OTSU method is as follows:
for any image I (x, y), the image size is M × N, the segmentation threshold of the foreground background is assumed to be T, the segmentation threshold is 255 if the segmentation threshold is larger than the threshold, otherwise the segmentation threshold is 0, the proportion of target pixels belonging to the foreground in the whole image is w0, the gray average value of the target pixels is u0, the proportion of pixels belonging to the background in the whole image is w1, the gray average value of the target pixels is u1, the gray average value of the whole image is u, and the inter-class variance is g; the number of pixels in the image smaller than the threshold T is N0, and the number of pixels equal to or larger than the threshold T is N1.
For the OTSU method, T when the variance is maximized is the threshold value.
Step five: and image data is accelerated, a GPU image acceleration processor is adopted to convert and transmit original image data to a logic end of a control host, the logic end carries out logic control on the whole cooling bed through the obtained image processing data, sends a control instruction to a PLC for controlling the cooling bed behavior, and sends a command to a communication server for information updating control.
Further, the image processing in the second step includes the following specific steps:
(1) selecting a target area, namely adaptively selecting four coordinate points in an image, wherein a quadrangle formed by enclosing the four coordinate points comprises the target area to be processed;
(2) perspective transforming the image, mapping the image of the selected target area from a two-dimensional view plane to a three-dimensional view plane by using the following mapping formula,whereinrepresenting points before transformation, before transformation𝑤A value of 1, (U, V, 1) in three-dimensional representation, mapped to three-dimensional by matrix transformation；
Then the following mapping formula is used to re-apply theThe image is again mapped from the three-dimensional view plane onto the two-dimensional view plane,and completing perspective transformation processing of the image.
Further, as shown in fig. 3, the specific step of adaptively selecting four coordinate points in step (1) is as follows:
A. acquiring relevant parameters of a camera, wherein the relevant parameters of the camera comprise a field range and an angle alpha of camera shooting, and the arrangement height h of the camera0Distance l from camera to laser line0Distance l from camera to the nearest side of cooling bed1And the width l of the laser line obtained by cutting2；
B. Calculating to obtain the horizontal straight line distance l from the camera to the nearest side of the cooling bed by using the calculation formula of the side length of the right-angled triangle through the acquired camera parameters3And the horizontal linear distance l from the camera to the laser line4；
C. Width l of laser line obtained by cutting2Obtain the coordinates w of two end points1And w2；
D. By calculating l4And l3And the coordinate point w1And w2Four coordinate points p of the target area can be obtained1，p2，p3，p4。
Furthermore, the logic control in the fifth step further comprises the step of using a convolutional neural training network and an intelligent algorithm for constructing deep learning, and performing deep learning and training on various control logic instructions generated by the cooling bed, and intelligently identifying and judging the control state of the cooling bed.
The basic principle of median filtering is: firstly, a proper square area is determined to be used as a neighborhood of a certain central pixel point, all the pixel points in the selected neighborhood are sorted according to the gray value, and the middle value of the group of sequences is taken as the gray value of the selected central pixel point to be output. Defining the intermediate value as follows, if the group of sequences contains odd number of pixel points, the gray value of the intermediate pixel point can be used as an output value; and if the group of sequences contains even number of pixel points, summing the gray values of the middle two pixel points and taking the average value as an output value. Because the window can slide, the image can be conveniently smoothed by sliding up and down, left and right.
The basic idea of median filtering can be expressed as:
wherein,the operation pixel point is represented and displayed,meaning that all values in the window are arranged in a monotonic order (from large to small or small to large) and then intermediate values are taken. It assumes that the center pixel of the window is a noise point, and the pixels in the neighborhood of the center pixel are signals except the noise point, and after arranging the signal points according to the monotone sequence, the gray value of the middle point is given to the selected center pixel. However, the precondition is that a threshold needs to be set to distinguish the signal point from the noise point, and the value of the signal point is substituted for the value of the noise point, so that the median filtering operation is meaningful, and the selection of the threshold is particularly critical. Therefore, if the threshold is properly selected, the median filtering can accurately distinguish and remove noise points, and meanwhile, image detail information is protected from being lost.
As can be seen from the above description and illustration of the present invention, the advantages of the present invention compared to the prior art are:
according to the scheme, the control of the cooling bed is realized by means of machine vision, the equipment can sense and dynamically sense the information of the cooling bed area, can feed back to a logic part according to a sensing result to give a command and correct, and finally, by constructing the learning of a deep learning machine neural network and an intelligent algorithm, the learning of various control data generated by the cooling bed is realized, and the self-state judgment and control of the cooling bed are realized. The scheme realizes high-precision control and rapid logic processing control of equipment, realizes intelligent operation of a cooling bed control technology, promotes intelligent development of the steel industry process, and has a remarkable effect of improving the whole process production efficiency of the steel industry.
The above description is only an embodiment of the present invention, but the design concept of the present invention is not limited thereto, and any insubstantial modifications of the present invention using this concept shall fall within the scope of infringing the present invention.
Claims (8)
1. The utility model provides a cold bed intelligence control system based on machine vision which characterized in that: the system comprises a cooling bed, an image acquisition device, a control host, a communication server and monitoring display equipment, wherein the cooling bed is controlled and executed by a PLC (programmable logic controller), and the image acquisition device is arranged above the cooling bed in a matching manner and is used for acquiring image information of a cooling bed area; the control host is respectively connected with the image acquisition device and the monitoring display equipment phase control, and is connected with the cooling bed phase control through the communication server; the communication server is also connected with the monitoring display equipment.
2. The machine vision-based cooling bed intelligent control system of claim 1, characterized in that: the image acquisition device comprises industrial cameras with high resolution, laser transmitters and trigger signal controllers, wherein the industrial cameras are arranged above two sides of the cooling bed respectively and symmetrically, the laser transmitters are used for assisting in positioning the position of the steel plate, the trigger signal controllers are respectively connected with the industrial cameras and the control host, and the trigger signal controllers are activated by image signals of the industrial cameras and then are connected with the control host.
3. The machine vision-based cooling bed intelligent control system of claim 1, characterized in that: the control host comprises an image processing module and a logic processing module, the image processing module is respectively connected with the image acquisition device and the logic processing module, and the logic processing module is connected with the cooling bed phase through the communication server in a control mode.
4. The machine vision-based cooling bed intelligent control system of claim 3, characterized in that: the logic processing module is also constructed with a deep learning convolution nerve training network and an intelligent algorithm, and is used for deep learning and training various control logic instructions generated by the cooling bed and intelligently recognizing and judging the control state of the cooling bed.
5. A use method of a machine vision-based cooling bed intelligent control system is characterized in that: the using method comprises the following specific steps:
the method comprises the following steps: acquiring a cold bed image, namely acquiring an image of a cold bed area by an image acquisition device arranged above a cold bed, and transmitting collected image data information to a control host to finish data acquisition and transmission;
step two: image processing, namely, the control host performs target selection and perspective transformation processing on the image data information uploaded in the step one;
step three: filtering the image, namely filtering the image subjected to perspective transformation in the step two by adopting a median filtering denoising algorithm to remove noise points of the image;
step four: performing steel plate image segmentation, namely performing threshold segmentation on the target image obtained in the step three by adopting an OTSU threshold processing algorithm to completely extract the steel plate target image from the image, forming a whole or partial pixel set of the steel plate target image, and finally finding out a partial or whole outline of the steel plate target image;
step five: and image data is accelerated, a GPU image acceleration processor is adopted to convert and transmit original image data to a logic end of a control host, the logic end carries out logic control on the whole cooling bed through the obtained image processing data, sends a control instruction to a PLC for controlling the cooling bed behavior, and sends a command to a communication server for information updating control.
6. The use method of the machine vision-based cooling bed intelligent control system is characterized in that: the image processing in the second step comprises the following specific steps:
(1) selecting a target area, namely adaptively selecting four coordinate points in an image, wherein a quadrangle formed by enclosing the four coordinate points comprises the target area to be processed;
(2) perspective transforming the image, mapping the image of the selected target area from a two-dimensional view plane to a three-dimensional view plane by using the following mapping formula,whereinrepresenting points before transformation, before transformationA value of 1, (U, V, 1) in three-dimensional representation, mapped to three-dimensional by matrix transformation；
Then the image is mapped again from the three-dimensional view plane to the two-dimensional view plane by using the following mapping formula,and completing perspective transformation processing of the image.
7. The use method of the machine vision-based cooling bed intelligent control system is characterized in that: the specific steps of adaptively selecting four coordinate points in the step (1) are as follows:
A. acquiring relevant parameters of a camera, wherein the relevant parameters of the camera comprise a field range and an angle alpha of camera shooting, and the arrangement height h of the camera0Distance l from camera to laser line0Distance l from camera to the nearest side of cooling bed1And the width l of the laser line obtained by cutting2；
B. Calculating to obtain the horizontal straight line distance l from the camera to the nearest side of the cooling bed by using the calculation formula of the side length of the right-angled triangle through the acquired camera parameters3And the horizontal linear distance l from the camera to the laser line4；
C. Width l of laser line obtained by cutting2Obtain the coordinates w of two end points1And w2；
D. By calculating l4And l3And the coordinate point w1And w2Four coordinate points p of the target area can be obtained1，p2，p3，p4。
8. The use method of the machine vision-based cooling bed intelligent control system is characterized in that: and the logic control in the fifth step further comprises the step of using a convolutional neural training network and an intelligent algorithm for constructing deep learning, and the convolutional neural training network and the intelligent algorithm are used for performing deep learning and training on various control logic instructions generated by the cooling bed and intelligently identifying and judging the control state of the cooling bed.
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